Bought a rough XR back in June this year which needs a fair bit of work. It came with a few nice extras but otherwise was pretty bad. My plan is to restore it back to its former glory, or at least get it as good as I can without breaking the bank.

On closer inspection I found that the countershaft is worn and will need to be replaced..

Along with the countershaft the bike needs a new clutch, new swingarm bearings, FCR40 carb boot adapter to use the std airbox as I dont like the idea of the cone filter. I have a replacement transmission, new clutch, new brakes (caliper and disc sm setup) and various other parts ready to go..

The engine will be getting stripped and depending on what I find may have new bearings and a new rod & piston while I am in there.

I am nearly ready to strip the motor and get the frame, swingarm and subframe powder coated along with a few other bits..

I don't get it Burp? You think all that will need doing or not? Never had to rebuild the motor on any of the other XR's I have had so this is all new to me. Not sure what to expect really, if the countershaft is wrecked I was just guessing the rest of the motor might be too!

Sorry, what I mean is that when you open an engine - which is quite a bit of work in any case - you replace ALL that is needed. And, this thing being old already (10+ years!) means I'd renew all what is a bearing or seal for starters, plus whatever you will find.... and I bet that will be more than just the CS.Pay attention to everything but especially the crank, and use the workshop manual (which you DO have I hope?) for the various things to check.Hey, you'll end up with 2 things: a new engine plus the knowledge all is fine, so piece of mind for a long time to come!Have fun!

Ok cheers. Yes I used to work for a honda dealer here in South Wales so have 'borrowed' the workshop manual. Plus my uncle in law is one of the mechanics who has worked there for 15 years so he will be doing the motor work for me. I will post up what I find in the next few weeks and take plenty of pics..

Going to the powder coaters tomorrow to drop some stuff off so will get some before pics. Need to get the motor cleaned before it comes apart too. By the looks of the bike it hasn't had much off road use, but that's why the countershaft is wrecked. Lots to do..

You dont need to buy the machinery just have the part made by someone who already have the equipment , the cost to add one small part to 1,5 X 3 meter sheet of metal they are commonly using its very small , and it takes 10 minutes to draw the part in the CAD software .